Machine and method for preparing a door and door frame for prehanging such door



Aug. 2, 1966 R. M. SHEFFIELD ETAL 2 MACHINE AND METHOD FOR PREPARING A DOOR AND DOOR FRAME FOR PREHANGING SUCH DOOR Filed July 22, 1963 7 Sheets-Sheet 1 INVENTORS \fim N RICHARD M. SHEFFIELD 8 ROBERT I*-J.'NORLIE.

EV wfl gbw ATTORN EYS Aug. 2, 1966 R. M. SHEFFIELD ETAL 3,263,723

MACHINE AND METHOD FDR PREPARING A DOOR AND DOOR FRAME FUR PREHANGING SUCH DOOR Filed July 22, 1963 fiheats-Sheet 2 A'TTO RNEYS I nm Ezv"r0125 RICHARD M. SHEFFKELD ROBERT N. NORLIE 3,263,723 DOOR Aug. 2, 1966 R. M. SHEFFIELD ETAL MACHINE AND METHOD FOR PREPARING A DOOR AND FRAME FOR PREHANGING SUCH DOOR 7 Sheets-Sheet 5 Filed July 22, 1963 INVENTORS RICHARD MSHEFFIELD ROBERT N. NORLIE 6 A, 777 441+ Ma ATTORNEYS INVENTORS RICHARD M. SHEFFIELD '7 Sheets-Sheet 4 FIG.

R. M. SHEFFIELD ETAL FRAME FOR PREHANGING SUCH noon RQBERT N! NORLJE 6% 777M444.

MACHINE AND METHOD FOR PREPARING A DOOR AND DOOR Aug. 2, 1966 Filed July 22, 1965 ATTORNEYS g- 1966 R. M. SHEFFIELD ETAL 3,263,723

MACHINE AND METHOD FOR PREPARING A DOOR AND DOOR FRAME FOR EREHANGING SUCH DOOR Filed July 22, 1963 'T Sheets-Sheet INVENTORQ RICHARD M. SHEFFIELJI) ROBERT ME MQRLJE.

' 7674.14, WALL/L 1- 70412 AT TQRNEYSR Aug. 2, 1966 R. M. SHEFFIELD ETAL 3,263,7 3

MACHINE AND METHOD FOR PREPARING A DOOR AND DOOR FRAME FOR PREHANGING SUCH DOOR Filed July 22, 1963 7 Sheets-$heat 6 /R!CHARD M. SHEFFIELD I ROBERT N. NORUE 5 mil-M ATTOR NEV$ Aug. 2, 1966 R. M. SHEFFIELD ETAL 3,263,723

MACHINE AND METHOD FOR PREPARING A DOOR AND DOOR I FRAME FOR PREHANGING SUCH DQOR Filed July 22, 1965 '7 Sheets- Sheet '7 FIG. 2 274 262 265 P III....

255 n 266 264 254 I'll 26 59 FIG. 22 263 INVENTORK RICHARD M. SHEFFlELETF ROBERT N. NORLBE ATTORNEYS United States Patent 3 263,723 MACHINE AND ME'lHOD FOR PREPARING A DOOR AND DOOR FRAME FOR PREHANG- ING SUCH DOOR Richard M. Sheflield and Robert N. Norlie, Chico, Calif., assignors to Norfield Manufacturing Co., Chico, Calif. Filed July 22, 1963, Ser. No. 296,519 7 Claims. (Cl. 144--326) This invention relates to a machine for preparing doors for hanging, and has for one of its objects the provision of a machine that is adapted to prepare a precut door and jamb for hingedly connecting them with greater speed and accuracy than heretofore.

In order to expedite the operation of hanging doors in a building, the building industry is adopting the method of precutting the doors and door frames to the desired size, so that the doors, after edging, will properly fit within the frames. By this operation the jambs are precut to the correct lengths and are rabbeted or dadoed along their upper edges to receive the ends of the head.

Thedoors themselves are of the proper length and substantially the proper width, but the longitudinally extending edge of the door that is opposite to the one that is to be hingedly connected to one of the jambs, must be edged or cut to provide a slight bevel transversely thereof to facilitate movement of said edge to and from closed position of the door. Also the doors are not formed with the latch opening and the lock opening for the lock and for the spindle that carries the knobs. These operations and the routing of recesses for the butts of the hinges vary according to direction the door is to swing.

Heretofore it has been the practice to chisel out gains or recesses in the jamb that is to carry the door to provide the recesses for one of the butts or leaves of the hinges. The door to be hung from this jamb is then similarly chiseled or routed out along the hinge edge for receiving the other butt or leaf of each of the hinges. These operations have heretofore been conducted separately at different places, but with indifferent consistency in the degree of accuracy that should be obtained, and the step has been quite costly from the standpoint of time. When it is considered that normally there should be approximately one-sixteenth of an inch clearance between the head of the door frame and the upper edge of the door, for inside doors after the door is hung, and a slightly larger clearance for outside doors, which must be provided for before the frame is assembled, and which clearances should be accurate irrespective of warpage or irregularities in the door and the jamb that is to be hingedly connected thereto, it is apparent why difliculty has been heretofore encountered in routing the jambs and doors for the hinge butts. Furthermore, in a properly hung door the butts should accurately fit the recesses.

One of the objects of the present invention is the provision of a machine that is provided with means for quickly edging the door, whether for a right or left swinging, and for drilling the openings for the knob spindle and latch, and for routing the recesses in the door edge and in the jamb, and which operations are performed with consistently high accuracy, both as to the relationships between the openings and recesses, i.e., their relative positions, and as to their individual proportions for the articles to be attached to the door and jamb.

Another object of the invention is the provision of a door processing machine that enables a relatively unskilled workman to form a precut door and the hingejamb of a door frame for the hinges that are to connect them, and to connect the door and jamb with the hinges, with absolute accuracy and within a small fraction of the time heretofore required to perform these steps.

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A still further object of the invention is the provision of a simple machine that is adapted to perform the work of edging a precut door, forming the openings for the latch spindle and latch, and forming the recesses in the hinge, jamb and door edge for the hinge butts, and which machine is simple, rugged, fast in operation, and substantially more economical to manufacture than heretofore.

Another object of the invention is the provision of a machine for preparing precut doors and the jamb therefor, for hanging the door from such jamb, which machine is more compact and economical to make and to maintain than heretofore, and in which machine all operations of the door are performed with the door on edge and horizontal in its greatest dimension to thereby provide better observation of all operations and ready accesss to all parts of the door than heretofore, and in which machine the jamb is alongside and parallel with the edge of the door that is to be connected therewith and is clearly visible to the operator at all times, and which jamb may .be hingedly connected with the door without effecting longitudinal movement of the door and jamb relatively after they have been routed out for the hinge butts and the latch and lock openings have been formed.

A still further object of the invention is the provision of an improved method of preparing a door and the jamb from which it is to be hung, for hingedly connecting them, and which method may include the step of edging the door along its edge that is opposite to the edge that is to be hingedly connected to the jamb.

Other objects and advantages will appear in the description and drawings.

In the drawings the words upper edge and lower edge used with reference to the door are the upper and lower edge of the door when in the machine, and not when the door is upright and hung.

FIG. 1 is a side elevation-a1 view of the machine from the side that will hereafter be called the front side, since it is the side at which the operator may stand during most of the operations. 1

FIG. 2 is an enlarged fragmentary sectional view taken generally along line 2-2 of FIG. 1 to show certain parts at the front side of the machine.

FIG. 3 is an enlarged, fragmentary sectional view taken along line 3-3 of FIG. 1.

FIG. 4 is a side elevational view of the machine as seen from the side opposite to the side seen in FIG. 1, the machine being shortened in length to accommodate the sketch.

FIG. 4a is an end elevational view of a portion of the machine as seen from line 4a-4a of FIG. 4.

FIG. 5 is a fragmentary slightly enlarged cross sectional view taken along line 5-5 of FIG. 4.

FIG. 6 is an enlarged, fragmentary cross sectional view of part of the machine as seen from line 6-6 of FIG. 4.

FIG. 7 is a sectional view of the portion of the machine shown in FIG. 6 as seen from the line 7-7 of FIG. 6.

FIG. 8 is an enlarged fragmentary perspective view of a portion of the left-hand end of the machine of FIG. 1, generally as seen from line 88 of FIG. 4.

FIG. 9 is a semidiag-rammatic View of the door clamping means that is at the right hand end of the machine as shown in FIG. 1, the view being substantially at a right angle to the door clamping means as seen in FIG. 1, so as to show both of the clamps.

FIG. 10 is a semidiagrarnmatic view of the elevating means for the drill and motor that drills the latch opening in the lower edge of the door after the door is clamped by the clamping means of FIG. 9 and which view shows the linkage as it generally appears from the same side as appears in FIG. 1.

FIG. 11 is a semidiagrammatic view of the means for moving the drill and motor for performing the step of drilling the opening for the lock, the view being substantially as the elements would appear looking at the machine from the right hand end of the machine shown in FIG. 1 and toward the left.

FIG. 12 is a semidiagrammatic view showing the means for moving and supporting the motor and drill of FIG. 11 at different levels so as to form the lock opening in the door at different distances from the lower edge.

FIG. 13 is a fragmentary perspective view illustrating the router in position over the upper edge of the door and over the jamb, for routing them for the hinge butts, which view also shows the router mounting structure and the gage structure for controlling the length of the recesses that are to be routed out.

FIG. 14 is a reduced side elevational view of the router mounting means, the router being held in a nonoperative elevated position and the jamb and part of the jamb support and the rod supporting the router for movement being in cross section.

FIG. 15 is an enlarged bottom plan view of the router support.

FIG. 16 is a cross sectional view taken along line 16- 16 of FIG. 15.

FIG. 17 is a perspective view of a door and a jamb in the positions they occupy whenin the machine of FIG. 1 showing the portions routed out for the hinge butts and the openings for the latch shaft and latch, and portions of the machine are diagrammatically illustrated to facilitate a description of the method.

FIG. 18 is a reduced, fragmentary side elevational view of a door hinge in the door frame, showing the crack or space that should be provided between the head of the frame and the door, and showing the uppermost hinge.

FIG. 19 is an enlarged, fragmentary cross sectional view, illustrating the bevelled vertical edge of the door opposite to the hinged edge.

FIG. 20 is a fragmentary perspective view similar to that of FIG. 8 as seen from the opposite side thereof, but showing a final step that may follow the step shown in FIG. 8.

FIG. 21 is a generally isometric view of a modified form of the portion of the invention that is shown in FIGS. 1316, portions being shown in cross section.

FIG. 22 is an enlarged, fragmentary cross-sectional view taken through the lower portion of the router in a direction longitudinally of the hinge jamb, part of which is shown.

FIG. 23 is a lower plan view of the router as seen from line 2323 of FIG. 22.

FIG. 24 is a greatly reduced side elevational view showing the modified gauge means, the door being indicated schematically in relation to said means.

Before making a detailed description of the apparatus r of FIGS. l16, a reference to FIGS. 17-19 will materially contribute to an understanding of the purpose of the invention and also the steps of the method.

A precut door is generally indicated at 1 in FIG. 17. This door is normally of the proper length, and is of substantially the correct width, but the edges are square, hence, one of the longitudinally extending edges must be slightly bevelled, as at 2 in FIG. 19, so as to properly clear the jamb when it is swung outwardly of the jamb 3 and away from the doorstop 4. Inasmuch as precut doors require 'bevelling the edge 2, there may be slight variations in the width of the doors, but after bevelling the width must be precise, since precut jambs and heads to form the frame are accurately cut, and the distance between the jambs will not vary.

After the door is hung in the frame, which is done prior to securing the frame in the door opening, it should have a clearance of approximately of an inch between the upper edge of the door and the head (FIG. 18) as at 6. This may vary slightly in the case of frames for the outside doors, due to the fact that the outside frames and doors may swell somewhat under the influence of moisture.

Whether or not the doors have the desired clearances and whether or not the latter are uniform depends upon the accuracy with which the recesses in the hinge jamb 7 and in the edge of the door adjacent to the hinge jamb are formed. It is equally important that the latch opening in the edge of the door that is opposite to the hinged edge thereof be accurately positioned relative to the keeper that is on the jamb 3, and also the through opening for the lock and latch operating shaft, that is at a right angle to the opening for the latch.

Referring to FIG. 17, the door 1, prior to forming the edge bevel and prior to other cutting operations thereon, is positioned vertically on its side and is moved longitudinally thereof in the direction of the arrow 8 between a stationary holddown guide 9 and a pair of drive rollers 10, 12 that drive the door endwise in the direction of said arrow 8. A rotary cutter 13 between said rollers 10, 12 bevels the lower edge of the door, as the door appears in FIG. 17, it being understood that said lower edge is the vertical edge 2 of the door, when the latter is hung, and which edge may be called the latch edge for convenience, since it is the edge from which the latch will project, being the free edge opposite to the hinge edge, the latter being identified by the numeral 14 (FIGS. 17, 18).

The drive roller 12 finally drives the door to approximately the position shown in FIG. 17, the operator moving the door past a pivot-ally supported positioning pawl 15, and then reversely against said pawl, to the position shown in FIG. 17.

In this position the door may be supported on guides 16, with hinge edge 14 alongside and parallel with the support on which the hinge jamb 7 is supported. In the arrangements shown in FIG. 17 a jamb stop 17 engages the end of said jamb, or preferably the shoulder 18 of the rabbet formed across the end of the jamb, or of the similar shoulder of a dado, and against which one end of the head 5 of the door frame is adapted to be supported in the finished door frame (FIG. 18). Both the latch jamb and the hinge jamb have the same shoulder.

The shoulder 18 of jamb 7 is offset, in a direction longitudinally of the jamb a predetermined distance, usually of an inch in a direction outwardly of the plane in which the near edge 19 of the door is positioned.

With the hinge jamb and the hinge edge of the door in the positions above described, the next steps of routing out the recesses in said hinge edge and door edges commence.

A conventional router 29 having a vertical downwardly projecting router bit 22 is slidably supported on the jamb 7 or hinge edge 14 for cutting into the marginal portion of the jamb and the hinge edge 14 of the door a predetermined distance to form recesses 23, 24 which are approximately the thickness of the hinge butt adapted to be seated in each recess. The width of each recess is equal to the width of each butt, and the length is the length of each butt.

The router assembly may carry a pin 25 that is adapted to be positioned in an upwardly opening recess 26 formed in a gauge member 27 for controlling the length of each recess, or the movement of the router bit longitudinally of the door, and which recess 26 also positions the cutter at the points where the recesses for the butts are to be formed. A suitable width control member 28 limits the width of the recesses 23, 24 to equal the width of each hinge butt, and a control member 29 also on the router assembly is movably disposed between the door 1 and jamb 7 to cooperate with the width control member 28 and router, to insure the recesses 23, 24 being of the same width. All the operator is required to do for forming the recesses 23, 24 in the jamb 7 and in the hinge edge 14 of door 1 is to position the router assembly so that pin 25 is in the proper recess 26, and so that the pin 29 is between the door and the jamb, and by manual manipulation of the router over the marginal portion of the jamb and over the jamb edge of the door, within the limits imposed by the recess 26 in the gauge bar 27 and within the limits imposed by the member 28 and the two recesses 23, 24 will be formed to exactly the correct length and width and these recesses will be directly opposite to each other. Also said recesses will be absolutely square with the edge 14 and the jamb 7.

Other recesses in gauge bar 27 are positioned for forming other recesses in the door edge and in the j-amb, for one or more other hinges. These recesses 26 are, of course, properly positioned with respect to the stop pawl so as to be in the right position relative to the ends of the door. 1 Either before or after the recesses for the hinge butts may be formed the latch opening or passageway 30 is formed by a motor driven drill 32 carried by a vertically reciprocable motor 33, and either before or after the passageway 30 is formed, the lock passageway or opening 34 is formed by a drill 35 carried by a horizontally reciprocable motor 36.

All of the above operations are conducted while the door is stationary after it has been driven past the edge cutter 13 and after it and the jamb 7 have been positioned alongside each other with one of their ends in a predetermined position relative to each other. 1 The operator may then quickly screw one of the hinge butts into recesses 23 and the other hinge butts in recesses 24. Of course, one of the hinge butts may first be secured in the recesses 24, and then the other hinge butts may be secured in recesses 23, and the jamb 7 will be secured to the door. Naturally pin 29 on the router assembly is elevated out of the space between the jamb and door in order for the jamb and door to be hingedly connected.

It will be apparent that no possible error can occur by the above procedure since the recesses 23, 24 will accurately and snugly receive the hinge butts and the recesses will be exactly opposite to each other, and the shoulder 18 will be exactly the desired distance beyond the adjacent end edge of the door (which in this instance will be the upper end in the finished door when the door is vertical).

The remaining operations of plumbing the jambs 3, 7 in a doorway with the head 5 seated against shoulders 18 and against the jambs, is quickly performed in the usual manner, and the job will be completed within a Referring now to the other views for a more detailed description of the machine, the stationary frame of the machine comprises a vertically disposed, horizontally elongated plate 37 (FIGS. 1, 4) having a pair of vertically extending laterally opening channel strips 38, 39 rigid therewith adjacent to opposite ends thereof. These strips are thus part of the stationary frame and are frame members, and the open sides of the channels are directed rearwardly. The words front, forward, rear and rearward and words of similar connotation will hereafter be used with respect to the position of the operator, who normally is at the side of the frame that is opposite to the side to which the open sides of the channel members 38, 39 are directed. FIG. 1 shows the front side of the machines. FIG. 4 shows the rear side. The member 38 is at the feed" end of the machine at which end the door 1 is introduced and member 39 is at the discharge end, or at the end from which the door is discharged.

Channel or frame member 38 has a vertically extending post 40 slidably held therein and the channel or frame member 39 has a similar post 42 similarly held therein (FIGS. 1, 4, 5). A vertically extending rack 43 is secured against the rear face of post 40, and a similar rack 44 is secured against the rear side of post 42.

Alongside and parallel with the rack 43, and also secured to post 40, is a vertically extending strip 45 formed with a vertical row of spaced openings 46 that are directed rearwardly of the post 40.

Journalle-d for rotation on rearward extensions of the sides of channel members 38, 39 is a horizontal shaft 47 (FIGS. 4, 5) which shaft has spur gears 48, 49 secured thereto, and which gears have their teeth in mesh with the teeth of racks 43, 44 respectively. The end of shaft 47 adjacent to the channel member 38 projects from the latter and carries a sprocket wheel 50. A jack shaft 52 spaced below and parallel with shaft 47 (FIGS. 1, 4) is journalled for rotation on the stationary frame of the machine and projects rearwardly of the feed end of the machine, and has an arm and handle 53 (FIG. 1) secured thereto for manual rotation of said shaft 52. A sprocket wheel 54 ('FIG. 4) is secured on said shaft 52 and a sprocket chain 51 connects sprocket wheels 50, 54.

By the above structure upon actuation of the handle and arm 53 to rotate shaft 52 the shaft 47 and gears 48, 49 will be rotated in one direction or the other to simultaneously elevate or lower the posts 40, 42.

A horizontal locking pin '55 is slidably supported for horizontal movement in a bearing 56 (FIG. 5) carried on a plate 57 secured across the top of the flanges of channel member 38, which pin is spring-urged by a spring 58 (FIG. 5) to enter any of the openings 46 (FIG. 4) in strip 45 that is opposite thereto for supporting the posts 40, 42 at different degrees of upward extension from the channel members 38, 39 upon manually retracting the pin from .the opening 46 in which it is positioned.

Secured to the upper end portions of posts 40, 42 is a horizontally extending bar 59 (FIGS. 1, 3, 4). This bar extends across the forwardly facing sides of posts 40, 42 and provides a laterally forwardly facing surface against which one laterally facing side of the upper portion of the horizontally extending door 1 (indicated in dot-dash lines in FIG. 3) is adapted to slidably engage.

Rigid with, and spaced above, the bar 59 at the feed end of the machine (left end as seen in FIG. 1) is a horizontally elongated angle strip 60. This strip 60 is parallel with bar 59 and one leg '63 (FIG. 3) of the angle strip is horizontal to extend over the upper edge of the door 1 when the latter enters the fee-d end of the machine, while the other leg 62 of which is adapted to extend over the side of the door that is opposite to bar 59. By this structure the bar 59 and strip 60 cooperate to provide an upper guide means and hold-down for the door at the feed end of the machine (FIG. 3). The function of the hold-down 9 already mentioned in describing the method (FIG. 17) is performed by bar 59 and strip 60. The vertical adjustment of posts 40, 42 provides for the accommodation of doors of different widths.

Projecting horizontally from the feed end of the machine, and away from said end, is a horizontally extending, upwardly opening channel strip 64 (FIG. 1), one end of which is connected by a horizontal pivot 65 with the feed end of frame member 37, as best seen in FIG. 1, while the other end of the channel member may have a depending leg 66 connected therewith for supporting said strip horizontal. The strip 64 may thus be swung upwardly to vertical position when the machine is not in use. This strip functions to receive, support, and to guide the door to the machine at the desired level, and the upper edge of the horizontally extendingdoor will pass 'below the leg 63 of the strip 60 and between leg 62 and bar 59 when the door is moved from left to right, looking at FIG. 1, and into the machine.

A lower horizontally extending. wooden bar 67 is secured .to frame member 37 (FIGS. 1, 2) at the forward side of the latter at a level slightly above the level of the channel strip 64, and this bar 67 is parallel with the bar 59, and is adapted to slidably engage the side of the door that faces the plate or frame members 37 as the door moves into the feed end of the machine. Thus bar '59 is in a position so that the door will be in a vertical plane when it is moved from the feed end of the machine toward the discharge end.

Adjacent to the feed end of the machine and projecting forwardly of frame member 37 is a rubber tired roll er '68 (FIGS. 1, 2) that is supported on said member 37 for rotation about a generally horizontal axis. The upper surface of this roller is preferably slightly above the level of the door supporting bottom of the channel strip 64, but the roller is yieldably held in such position so that it will yieldably hold the door, during movement of the latter, against the horizontal leg 63 (FIG. 3) of the angle strip 60. The means for mounting and for rotating this roller 68 will later be described, but at this point it may be noted that said roller drives the door to the pair of drive rollers designated 10, 12 in FIG. 17, that were mentioned in describing the method as shown in FIG. 17.

Horizontally spaced from the roller 68 in a direction away from the feed end of the machine and toward the discharge end thereof are a pair of horizontally spaced, rubber tired rollers 69, 70 (FIGS. 1, '2) that perform the functions of rollers 10, 12 of FIG. 17, and between rollers 69, 70, is the rotary cutter 72 that corresponds to cutter 13 of FIG. 17.

The rollers 68, 69 and 70 are respectively rigid on one of the ends of shafts 73, 74, 75, respectively (FIGS. 1, 4), and said shafts extend generally horizontally through openings in the frame plate 37 and project to the rear side of said plate a substantial distance.

Inasmuch as the supports for the roller shafts 73-75 are the same, a detailed description of the mounting for shaft 74 of roller 69 will suffice for all three, and such mounting is shown in detail in FIGS. 6 and 7.

A horizontally disposed plate 76 is pivotally connected along one of its edges to the rear side of the frame plate 37 by a horizontal pivot or hinge pin 77 so that plate may swing vertically about said pivot. Shaft 74, in turn, is below said plate 76 and is supported for rotation in bearings 78 that are secured to said plate.

Adjacent to the rear edge of plate 76 that is remote from the pivot 77, and above said plate, is a vertically disposed helical compression spring 79. This spring is adapted to react between the rear end of plate 76 and a cap 80 on the lower end of a vertically adjustable screw 82. This screw 82 threadedly extends through a member 83 that is rigid with the frame plate 37. The forward edge of the plate 76 may extend below the rearwardly projecting ears 84 that carry pivot 77 to limit the downward movement of the plate 76, but normally, when the spring 79 is under tension and before a door is moved to a position between said roller and the hold-down bar or angle strip 60, the shaft 74 may be slightly tilted to hold the upper surface of the roller elevated above the level of the bottom of the door supporting channel 64 so that a door, when moved between the hold-down angle strip 60 and the roller 69, will be yieldably moved downwardly to yieldably hold the upper edge of the door against said hold-down strip. It is the upper edge of the horizontally disposed door that must be maintained at the desired uniform level, since the lower edge will be bevelled by the cutter 72, and the cutter 72 will function to cut the doors to uniform width as well as performing the bevelling operation. Thus, the tension of spring 79 must always be such that it will overcome the weight of the door.

As already mentioned, rollers 68 and 70 have the same pivoted and yieldable mounting as above described for roller 69.

A sprocket wheel 84 is secured to the rear end of shaft 74 and a similar sprocket wheel 85 (FIG. 4) is secured to the rear end of shaft 73 mounting roller 68. A sprocket chain 86 extends over sprocket wheels 84, 85. A sprocket wheel 87 (FIG. 6) is also secured on the rear end of shaft 8 74, and this sprocket wheel 87 is connected by a chain 88 with a sprocket wheel on shaft that is identical with sprocket wheel 85. Also secured on shaft 75 is a sprocket wheel 89 (FIG. 4) that is connected by a chain 90 with a sprocket wheel 92 on the driven shaft of a gear transmission driven by motor 93.

It is thus seen that rollers 68, 69 and 70 will all be rotated in the same direction and at the same speed for driving the door from the feed end of the machine toward its discharge end.

The rear ends of the shaft 73, 74, 75 all project rearwardly of pivotally supported plates that carry the shafts, and three chain tighteners are provided to maintain the chains taut during the pivotal movement of the shafts and at all times, as will be described.

The plates 76 that support the shafts 73-75 may be formed with upstanding ears 94 at their rear corners (FIG. 6) and horizontally extending bars 95 extend between the adjacent pairs of plates 76 and are bolted at their ends to one of the ears on each adjacent pair of plates.

As seen in FIGS. 4, 6, and upwardly inclined arm 96 is pivoted at a point intermediate its ends to each bar 95, as at 97 (FIG. 6) and a helical spring 98 (FIG. 4) connects one end of each bar 95 with a member rigid on the frame 37. The lower end of each arm 96 rotatably supports a sprocket wheel 99 that engages the lower run of each chain 86, 88 for maintaining said chains taut.

An arm 100, similar to each arm 96, is pivotally supported at a point intermediate its ends, as at 102 (FIG. 4) and a sprocket wheel 103 on the lower end of said arm engages the lower run of chain 90, while a spring 104 connects the upper end of arm with a member rigid with frame 37 to maintain tension on the chain 90.

Insofar as the cutter 72 is concerned, its shaft 105 extends through the frame plate 37 and its rear end carries a pulley 106 (FIG. 4) that is connected by a V-belt or any other suitable means with a pulley 107 driven by motor 109. The cutter is stationary insofar as any piv otal movement is concerned, and its cutting edges are formed to accurately bevel the lower edge of the door as the door is driven therepast. As seen, the distance between the cutter 72 and the leg 63 of strip 60 determines the width of the finished door.

At the front side of the machine, a rubber tired roller 109 (FIGS. 1, 2, 7) above and adjacent to roller 69 is rotatable on a vertical shaft that is carried on at the outer end of a horizontally extending leaf spring 110. Spring 110 extends from roller 109 toward the feed end of the machine, and its end opposite to said roller is held rigid on a clamp block 112 that, in turn, is tightly, but adjustably, clamped on a stationary vertical rod 113. This rod 113 is secured to the frame plate 37 by a bracket arm 114 (FIGS. 1, 6). Thus roller 109 functions to yieldably hold the door against the hardwood slide 67 adjacent to the point where the edging cutter 72 will bevel the lower edge of the door.

A horizontally extending housing 111 is adapted to be supported at one end from rod 113 to extend over the rollers 69, 70 and cutter 72 as a safety measure, and a manually actuatable set screw 115 is adapted to releasably secure the housing rigid relative to the rod 13 (FIG. 1).

In the apparatus up to this point, it is seen that the door 1 will be trimmed by the cutter 72 in FIG. 1 or 13 in FIG. 17 to exactly the correct width and with the correct angularity of the lower edge relative to the planar sides of the door, it being understood that the lower edge will be the vertical edge of the hung door that is opposite to the edge from which the door will be hung. The roller 70 will drive the door to substantially the desired position for routing out the recesses for one of the butts of the hinges.

The next steps are particularly important since the success in prehanging doors mostly depends upon the accuracy with which the recesses in the hinge-jamb and hinge-edge of the door are positioned and formed. I

After the door has been edged, which is the term used for cutting the edge 2 (FIG. 19) to the correct transverse angle and at the same time for reducing the door to the correct width, the door will be supported in a substantially vertical plane between a horizontally extending guide bar 116 and the bar 39, and on a horizontally extending support 117 leading to between a pair of vertically disposed clamps 118, 119 (FIGS. 1, 9). The level of support 117 is preferably such as to maintain the door, after it has been edged, so its upper edge is at the same level as when it is passing the cutter 72.

As the door is moving from the feed end toward the discharge end, a pawl 120 that is pivoted at 122 to an upward extension 123 of the upper angle strip 60 (FIGS. 1, 3, 8) will be swung upwardly about pivot 122 by the door to ride on the upper edge of the latter, and as soon as the trailing end 124 of the door passes the pawl, the latter will drop behind said trailing edge to the position shown in FIG. 8, and the operator will then slide the door backward slightly so the rear edge will be sure to snugly engage said pawl should the door have moved beyond the latter. The clamps 118, 119 will then be moved to tightly clamp the door therebetween and to rigidly hold the door stationary and vertical. These clamps and their operating mechanism are semidiagrammatically shown in FIG. 9, and when in clamping relation they are at the point where the latch opening 30 and the lock opening 34 (FIG. 17) are to be formed. It is to be understood that this portion of the description is applicable to preparing a door and jamb for hingedly connecting them for swinging the door in one direction. A later description will deal with the situation in which the door is to swing in the opposite direction.

The pawl 15, in FIG. 17, wherein the method is disclosed, corresponds in function and position to the pawl 120 in FIGS. 1 and 8.

In the semidiagrammatic view, FIG. 17, a horizontally extending gauge member 27 is shown. In FIGS. 4 and 8 the member corresponding thereto is designated 125 and is shown as being welded to the ends of vertically disposed webs 126 that, in turn, are secured to the bar 59 that has the laterally facing surface directed toward door 1 (FIG. 8). Thus the member 125 and webs 126 will move with bar 59 when posts 40, 42 are elevated or lowered. These webs 126 provide ribs extending at right angles to the member 125 and the upper edges of said ribs are coplanar and are adapted to support the hingejamb 7 fiat thereon with the upper surface of said jamb in the same plane as the upper edge of door 1. One longitudinally extending edge of said jamb is adapted to abut thelaterally facing surface of the member 125 adjacent to the upper edge of the latter, and the said jamb may project slightly above the upper edge of member 125 (FIG. 8). Inasmuch as member 125 is parallel with the upper edge of door 1, the hinge-jamb will be parallel with said upper edge.

As already explained with reference to FIG. 17, one end of the hinge-jamb 7 is rabbeted or dadoed transversely thereof to a predetermined depth to provide an axially facing shoulder 18 on which the head 5 of the door frame is supported (FIGS. 8, 18). Also, it has been explained that, after the door is hung on the hinge-jamb, a predetermined space 6 (FIG. 18) should be left between the head 5 and the upper edge of the door. The length of the hinge-jamb is such that the lower ends of the jamb will project below the lower edge of the door the desired distance for clearance between the lower edge of the door and the floor when said jambs are in position within the door opening for securing the door frame to the studding at opposite sides of such opening.

Referring back to FIG. 8 the jamb-stop 17 mentioned in connection with the method described with respect to FIG. 17 is indicated at 127 and is adjustably secured on one end of a cylindrical, horizontal bar 128 for movement axially of said bar to the desired adjusted position bymeans of a bolt 129. The bar 128 is supported on and secured rigidly to the outer end portions of horizontally extending supports at the ends of said bar, which supports, in turn, are rigidly secured at their opposite ends to the bar 59.

The jamb-stop 127 projects forwardly from said bar 128 so that its outer forward end portion is adapted to extend into the head rabbet or dado that is formed in one end of the jamb for said frame head 5, and thus when jamb 7 is positioned flat on said ribs 126 with the rabbet at its end directed upwardly, and with the rabbeted end of the jamb at the feed end of the machine, the jamb may be slid longitudinally on said ribs toward said feed end until the jamb stop engages the shoulder 18. The jamb-stop 127 is secured on bar 128 in a position in which the face thereof facing said shoulder 18 is one sixteenth of an inch closer to the feed end of the machine than the trailing edge 124 of the door where such clearance is desired, when said trailing edge is against pawl 120. Obviously by adjustment of the jamb stop, any desired clearance may be obtained.

The gauge member 125 is formed along its upper edge with a plurality of upwardly opening square recesses or notches 132 that correspond to the recesses 26 described relative to FIG. 17.

In an ordinary door there are usually only two hinges, the upper hinge to be positioned seven inches from the upper edge of the door and the lower hinge is preferably eleven inches from the bottom of the door. The invention is not to be restricted to such dimensions. They are used for purpose of description since they are standard.

In FIG. 8 the notch or recess 132 indicated therein is seven inches from a point along said upper edge that is even with or opposite to the trailing edge of the door or the outer end face of pawl 120, and a second correspond ing recess is formed at the other end of the member 125 that is eleven inches from a point that is even with the leading edge of the door 1 when said trailing end edge of said door is against pawl 120.

The distance between the opposite edges of each recess or notch 132 is approximately equal to the length of the leaf on each butt hinge.

In FIGS. 1, 4, a conventional vertically disposed router is indicated generally by the numeral 133. FIG. 13 is a view of the router assembly as generally seen from the rear upper side of the machine, the door 1 and hinge jamb 7 being indicated as well as member 125 and bar 128.

A cylindrical sleeve 134 is slidably on bar 128 longitudinally of the latter, said sleeve having adjustable bearing and positioning posts 135 threadedly extending therethrough and engaging bar 128 for slidabl y supporting said sleeve on said bar and for aligning the sleeve in the bar to insure a uniform and accurate support for a platform or table 136 that is positioned over the sleeve 134. A pair of coaxial hollow cylinders 137, 138 are secured together at one of their ends in telescopic relation and are secured on the upper side of said table 136 with said cylinders extending at a right angle relative to the gauge member 125 and cylinder 138 in a position adjacent to the latter with cylinder 137 spaced rearwardly therefrom. Obviously a single counterbored cylinder could provide the same structure.

A control pin 139 is centrally secured to the forward edge of the table 36 and projects forwardly thereof. Since the sleeve 134 is rotatable on bar 128, a well as slidable longitudinally of the latter, the forward edge of the table may be swung upwardly (FIG. 14) and the pin 139 will move upwardly with the table. When the table is in a horizontal position, as seen in FIG. 13, the pin 139 will enter whichever recess 132 is opposite thereto, and then the movement of table 136 longitudinally of bar 128 is equal to the distance between the opposite vertical edges of each recess. In FIG. 17, the control pin 25 corre- 1 1 sponds to the control pin 139 in the apparatus of FIGS. 13 and 14.

A rod 140 (FIG. 13) slidably extends through cylinder 138 and into enlarged cylinder 137 and is provided with a head 142 that is rigid with rod 140 and reciprocable in cylinder 137 with said rod. A lug 143 rigid with head 142 projects downwardly therefrom into a slot 144 in the lower side of cylinder 137 that extends longitudinally of cylinder 137. Thus rod 140 may reciprocate in the cylinders 137, 138 but will not rotate, and the closed end of slot 144 will act as a stop to engage the lug 143 for preventing withdrawal of rod 140 from the cylinders.

The forward end of rod 140 projects from the forward end of cylinder 138 and is rigidly secured to the rear end of a horizontally disposed router supporting plate 145. This plate 145 may be elongated in a direction longitudinally of rod 140 and supports a conventional, vertically disposed router motor 146 thereon with the router bit (FIG. 14) 147 projecting from the lower end thereof. Such motor is indicated at 21 in FIG. 17.

The plate 145 is formed with a relatively large central opening through which bit 147 projects in a downward direction, and a pair of generally parallel, spaced, opposed runners 148 project downwardly from plate 145 along two opposite edges thereof, which runners extend substantially parallel with the longitudinal axis of plate 145 (FIGS. 13, 15, 16). These runners are adapted to engage the upper surface of the hinge jamb 7 and the upper surface of the upper edge of door 1, according to which is being routed, and the bit 147 projects at its lower end below the level of the lower edges of said runners 148 a distance equal to the depth to which the recesses for the hinge leaves are to be formed. This depth normally is such that the outer surface of the butt or leaf in each recess is substantially flush with the adjoining surface of the hinge edge of the door, but no deeper, since a projection of the edge surface beyond the hinge would be likely to result in detrimental strain on the hinge screws with each closing of the door.

By the above structure it is seen that the length of the recesses to be routed out is controlled by the recesses 132 and control pin 139, while the runners 148 maintain the depth, and with respect to the latter it is also pertinent to note that the runners will also follow the surface contour of the jamb. Thus if the jamb should be bowed or warped, the depth of the recess that is cut will be the same, and when the jamb is secured in position in a door opening and is straightened, the recess will remain the same. This is important.

A control plate 149 (FIG. 15) extends transversely across the underside of plate 145 and is pivotally secured at one of its ends to plate 145 by a vertical pivot 150. This plate 145 is formed with a central slot 152 that may be formed about the axis of pivot 150, through which the router bit 147 projects. At the side of the slot 152 opposite to the pivot 158 said control plate 149' carries an upstanding pin 153 (FIG. 16) that extends through an arcuate slot 154 (FIG. 15 formed in the router supporting plate 145. A pair of helical springs 155, 156 extend oppositely outwardly of pin 152 above the plate 145 and generally longitudinally of slot 154, with the latter following an are about pivot 150 as a center, and extending equal distances to opposite sides of a straight line extending through pivot 150 and the bit 147. This line is parallel with the axis of bar 128 and springs 155, 156 are secured at their outer ends to adjustable lugs 157 adjustably secured to the upper side of the router supporting plate 145 to yieldably hold pin 153 with its axis in the same plane as the plane in which the axes of pivot 150 and bit 147 are positioned, and which plane is preferably at a right angle to the axis of cylinders 137, 138 when the router is inoperative before a routing operation.

The control plate 149 that is below and pivotally connected with the router supporting plate 145 also carries a pin 158 (FIGS. 15, .16) depending from the end of the control plate, the axis of which pin 158 is in the same plane as that in which the axes of bit 147 and pivot 159 and pin 153 are positioned, when the router is inoperative, and which pin 158 projects from said plate 149 a substantially greater distance than the bit 147. Thus springs 155, 156 function to yieldably hold pin 158 in the plane above mentioned as well as holding the pin 153 in said plane.

In operation, in routing out the hinge jamb 7 the handle 159 of the router is at the side thereof opposite to the rod 140, or at the front side thereof, and projects upwardly from plate 145 to which it is secured, for grasping by the hand of an operator. The manually actuatable switch 160 thereon is conveniently positioned at the lower end of the handle for actuation by the index finger of the right hand when such hand grasps the handle for manipulating the router. The switch and router motor are, of course, in an electrical circuit (not shown) for actuation of the motor to start and to stop the latter upon actuation of the switch.

During movement of the door 1 and hinge jamb 7 to the positions thereof shown in FIGS. 8, 17, the router assembly will be swung to the tilted position shown in FIG. 14 and it is held in this position by an angularly downwardly extending arm 162 that is secured at one end thereof to the table 136 adjacent to the rear edge of the latter, and the lower end of which arm is adapted to engage the member for holding the assembly in said tilted position with the router elevated. The control pin 139, and pin 158 as well as the router bit 147, will also be elevated so there will be nothing to interfere with the positioning of the door 1 and door jamb 7 in the positions shown in FIG. 8.

The center of gravity of the router assembly that is tiltable or swingable about the bar 128, is at the rear side of the axis of said bar when the assembly is tilted to the position shown in FIG. 14, hence it will not accidentally fall to horizontal position, yet a relatively slight effort will be required to swing the assembly to operative position over the door and hinge jamb, and the handle 159 is conveniently located for grasping by the operator to so move the router assembly.

In operation, after the hinge jamb 7 and door 1 are in the position shown in FIG. 13, the door may be clamped and held rigid between clamps 118, 119 (FIG. 9), the details of which will be described later on, and the router assembly is then moved along bar 128, axially thereof, to a position in which the control pin 139 will enter recess 132 that is opposite to the area to be routed out for the leaves of the butt hinge, when the assembly is swung down to routing position. However, the bit cannot engage the door or the jamb hinge, unless the depending pin 158 is in the space 163 (FIGS. 8, 13) that is between the hinge jamb 7 and door 1, and to enter such space the router must be moved forwardly from its position when the router assembly is in tilted position which movement will result in the rear end of the router supporting plate being spaced from the forward end of cylinder 138 a slightly greater distance than the distance between the rear end of slot 154 in the plate 145 a point centrally between said rear end and the middle of the slot. Thus it will be seen that the rear edge of slot 154 (FIG. 15 will limit the movement of the router bit transversely of the upper edge of the door starting from a position in which the pin 158 engages the adjacent edge of the door. In the same manner, the forward edge of slot 154 will limit the movement of the router bit transversely of the upper edge of the jamb, starting from an initial position in which pin 158 engages the side of the jamb that is adjacent thereto.

The control pin 139 being in the desired notch or recess 132 in the member 125 and the pin 158 being between the door 1 and hinge jamb 7, it only remains for the operator to start the router motor and to move the router between the limits of the vertical opposed edges slot 154 and pin 153, and in a matter of seconds the two recesses 23, 24 (FIGS. 8, 17) for each butt hinge may be formed with absolute precision as to positions, depth, width and length.

The distance the router bit projects below legs or runners 148 on the router supporting plate 145 determines the depth of the recesses; the opposed edges or sides of each recess 132 in member 125 determines the length of each recess 23, 24, and the length of slot 154 in the router supporting plate 45 determines the width of each recess. The pawl 15 and jamb stop 17 constitute positioning means for positioning the door and hinge jamb relative to the above described means for forming the recesses for the hinge butts, so that said recesses will be formed in exactly the right positions on the door and hinge jamb so the hinge, such as indicated at 166 in FIG. 20, will exactly fit the recesses when the hinge jamb is moved to a position adjacent to the door and the door and hinge jamb will also be spaced apart the desired degree with precise accuracy when the hinge butts are secured to the door and to the hinge jamb. Also, said pawl and jamb stop determine the positions of the lock opening and latch opening relative to the ends of the door.

Whether the step of securing the hinge jamb to the door 1 is before or after the latch opening 30 and the lock opening 34 are formed is immaterial, and said openings may be formed after the hinge jamb is secured to the door 1. However, the door, in any event, is rigidly held between clamping elements 118, 119 during the formation of said openings.

At the right hand end of the drawings, FIG. 1, the portion of the machine is illustrated where the clamps 118, 119 are positioned and where the openings 30, 34 are formed. These openings are along the free edge 2 of the door that is opposite to the hinge edge, which free edge is vertical after the door is hung (FIG. 18) and is in the door opening, but the position of the door when it is being processed in the machine is such that said edge is the lower edge.

When the door 1 is in the position indicated in FIGS. 8, l7 and 20, the clamping elements 118, 119 preferably cover the lateral sides of the door around the area in which the latch and lock openings are to be formed. Each clamp is preferably rectangular and covers a substantial portion of the door around the said areas, and each clamp has a metal backing plate 167 and a wood face plate 168 (FIG. 9). The face plates 168 are the plates that engage the opposite sides of the door, and each such plate may be formed with a pair of vertically spaced openings 169 (FIG. 1) through which the circular hole cutter or drill 170 (FIG. 11) is adapted to be moved when the cutter is in an upper position or in a lower position. The metal backing plate of each clamp may be formed with a vertically extending slot 172. Openings 169 are at the upper and lower ends of slots 172, and the openings come within the open areas of the slots so the metal backing plate will not interfere with the cutter 17.

a The provision of two openings is to enable the lock opening in each door to be formed different distances from the free edge of the door, and the cutter 170 can be adjusted to make a shorter or longer lock opening. Inasmuch as the two lock positions are standardized it is not necessary to provide for other positions, although it is obvious that any desired number may be provided.

The rigid frame 37 of the machine includes frameplates 173, 174 at the discharge end of the machine that are spaced apart longitudinally of the machine (FIG. 4) and reference to the frame of the machine includes these plates and any means rigid therewith to which any of the movable elements may be connected or supported for, movement.

A pair of parallel, vertical, stationary slide members 175 (FIGS. 4, 12) rigid with frame members 1 73, 174

support a vertically disposed plate 176 for vertical movement and a pair of parallel horizontally extending bars 177 (FIGS. 1, 4, l2) rigid with said plate support a platform 178 (FIGS. 4, 11) thereon for horizontal movement of said platform on said bars 177.

Cutter is held in a chuck on one end of the shaft of a horizontal motor 179 (FIG. 11) that is secured on platform 178.

Pivotally connected with the plate 176 at 180 (FIGS. 4, 12) is the upper end of a vertically extending bar 182 (FIGS. 4, 12) that has a lateral forwardly extending projection 183 (FIG. 12) rigid therewith intermediate its ends, which projection is adapted to be supported on a stationary rearwardly extending projection 184 (FIGS. 4, 12) on a stationary frame member 185 when the plate 176 is in a position supporting the motor 179 in the upper of its two positions. The lower end of bar 182 is pivotally connected with the end of a laterally projecting arm 187 that, in turn, is pivotally connected with a stationary part 188 of the frame. The pivot connection at 180 may be relatively loose, so that an operator may grasp the outer end of arm 187 and push downwardly to elevate projection 183 off its supporting projection 184, and then swing the handle laterally so projection 183 will clear projection 184 to permit the motor carrying plate 176 to be lowered for engaging said projection 184 for supporting the motor 179 in the lower of its two positions. As seen in FIG. 12, the stationary member 185 is offset forwardly relative to plate 176 so that the latter can move downwardly across the rear side of said member 185.

In the drawings the motor 179 is in the elevated position and, as already mentioned, it is movable horizontally on the bars 177.

Depending below the table or platform 178 is a lug to which one end of a bar 189 (FIG. 11) is pivoted by pivot 191. This bar 189 extends rearwardly and downwardly relative to its forward end where it is connected with platform 178, and then laterally (FIG. 4) to a point outside the end frame member 174, and then forwardly through a rigid guide member 190 to the forward side of the machine where it is pivotally connected with a vertically extending manually actuable lever arm 192 by a pin-slot connection. The lower end of arms 192 is pivotally connected with a stationary part of the machine at 193 (FIG. 11) while the upper end of the lever arm has a manually graspable knob 194 (FIG. 1). An electrical switch 195 (FIG. 4) is secured to the motor platform at one side thereof and a switch actuating element 196 is connected to a stationary part of the frame alongside the frame.

Referring to FIG. 11, upon the operator grasping knob 194 by the hand and swinging the upper end of lever 192 forwardly, the motor 179 and cutter 170 will be moved forwardly and the cutter will cut the lock opening 34 in the door. Switch 195 will automatically close the circuit to motor 179 upon the latter being moved forwardly and away from the switch actuating member 196, it being understood that the switch and motor are in an electrical circuit (not shown) for providing current to the motor. After the opening 34 has been cut, the switch 195 will be actuated by engagement with member 196 at the end of the return movement of the motor to open the circuit to the motor.

Directly below the lower edge of the door and in vertical alignment with a line extending to the axis of opening 30 is a vertically disposed upwardly directed drill 197 (FIG. 10) supported in the chuck of a vertically disposed motor 198 (FIGS. 1, 4, 10). Motor 198 is stationary on the rear side of a vertical panel 199 that, in turn, has a pair of vertically disposed parallel horizontally spaced bearings 200 (FIGS. 4, l0) rigid therewith slidably receiving a pair of stationary cylindrical, vertical guide members 202. Thus the panel and motor are guided for vertical reciprocable movement. As seen in FIGS. 1, 10 the guide members 202 depend from a stationary part 203 of the machine frame.

The vertical movement of the motor is effected by a manually actuatable, vertically extending lever arm 294 (FIGS. 1, 10) that is at the forward side of the machine, and which arm has a graspable knob 205 at its upper end. At its lower end arm 204 has a lateral extension 296 (FIG. 10) rigid therewith that is one arm of a crank portion pivotally connected by a pivot 207 to rigid part 2113 of the machine frame at a point intermediate the juncture between the arms of such crank portion. The other arm of said crank portion is pivotally connected at its outer end by a pivot 212 with the upper end of a vertically extending link 210 that, in turn, is pivotally connected at its lower end by a pivot 213 to an ear that is rigid with the lower portion of the motor supporting panel 199. An operator at the front side of the machine may elevate the motor and its drill 197 by swinging the upper end of lever arm 204 to the right to thereby move the motor supporting panel upwardly on guide rods 202, and a reverse swinging of the lever arm will result in lowering the panel to the lower end of its movement where a forward projection 209 at the juncture between arms 204, 296 will engage stationary frame member 203. Upward movement of the motor is limited by engagement between frame member 203 and plate 199.

A switch 214 that is in the circuit with motor 198 may be carried by the panel 199 for movement therewith to and from a stationary switch actuating member 215 for actuation in the same manner as the switch 195, so that the motor 198 will be automatically actuated for actuating drill 197 upon upward movement of the panel 199 and the circuit will be opened automatically to stop the motor upon the latter reaching the lower end of its movement.

Referring now to the actuating means for actuating the clamps 119, 118. FIG. 9 semidiagrammatically illustrates this mechanism, which view, taken with FIG. 1 that shows the same mechanism at a right angle to the view in FIG. 9, shows a vertically extending lever arm 216, which is provided at its upper end with a hand graspable knob 217 for manually actuating said lever. The lower end of lever 216 is formed with a laterally projecting extension 218 rigid therewith (FIG. 1), which extension is connected by a pivot 219 with a stationary part of the machine for swinging of said lever arm and its extension about said pivot. The outer end of extension 218 is connected by a pivot 220 with the upper end of a vertically extending link 222. The lower end of link 222, in turn, is pivotally connected at 223 with an ear that is centrally between the ends of a horizontal bar 224 (FIGS. 1, 9). i

The ends of bar 224 pivotally connect with one of the ends of a pair of opposed, parallel, relatively long arms 225 (FIGS. 1, 9) and the other ends are pivotally connected at 226 with the lower ends of a pair of opposed, vertical links 227, which links, in turn, are connected at points intermediate their upper and lower ends by coaxial horizontal pivots 228 that are rigid with the frame plates 173, 174. The upper ends of the links 227 are connected by coaxial horizontal pivots 229 with lugs secured to the rear of the rear clamps 119 adjacent to the lower edge of the latter, but spaced above said lower edge so that the upper end portions of the links 227 will extend over a sufficient portion of the back of clamp 119 to prevent the upper portion of clamp 119 from swinging toward the clamp 118 about pivots 220.

Clamp 118 is provided on its back, or forward side, with lugs corresponding to those on the back of clamp 119, that are connected by coaxial horizontal pivots 230 with the upper ends of a pair of parallel, horizontally spaced, opposed links 232 that correspond to links 227. These links 232 are pivotally connected by coaxial horizontal pivots 233 with frame plates 173, 174 at points intermediate the ends of said links. The lower ends of links 232 are connected by coaxial horizontal pivots 234 with one of the ends of a pair of relatively short links 235, and

the latter are connected at their opposite ends by coaxial horizontal pivots 236 with the long links 225 at a point spaced from pivots 226 the same distance as between each pivot 236 and the pivot at the end of the link 235 that is connected therewith. Each of the pivots 236 includes an extension that projects into a vertical slot 237 between guide bars that are rigid with the frame plates 173, 174 respectively.

By the above structure, upon swinging the arm 216 to one side about pivot 219, the bar 224 will be elevated to swing links 227, 232 so the clamps 118, 119 will move into clamping engagement with the door, which is the position shown in FIG. 9, and upon swinging the lever 216 in the opposite direction, the clamps will move apart. When they are in clamping relation a lock bar 238 that is pivoted to a stationary part of the frame by pivot 239 (FIG. 1) is adapted to be swung from a generally horizontally extending position out of engagement with extension 218 to a position frictionally engaging the underside of said extension at a point between pivots 219, 220 at one end thereof to prevent accidental release of the clamps when the latter are in clamping relation to a door. The locking bar 238 (FIG. 1) includes a lateral projection 24!) thereon that may be manually grasped to swing the locking bar into and out of locking relation with extension 213.

It is to be noted that in FIG. 9 only the links and their pivotal connectors (225-236) that are adjacent to the end plate 174 are shown, it being understood that corresponding links and pivots are adjacent to end plate 173.

The cutter 35 and drill 32 that are shown in FIG. 17 have their counterparts in cutter 170 and drill 197, and an upwardly opening channel strip 242 is at the end of the machine opposite to the strip 64, and is connected pivotally with the frame plate 174 in the same manner as strip 64 and functions to support the door when the latter is moved out of and away from the discharge end of the machine.

The rapid and accurate hinging of a door to the hinge jamb and the edging of each door, as compared with the conventional method, is believed to be apparent. The standard publication entitled Carpentry for the Building Trades by E. A. Lair and published by McGraw-Hill Book Company, Inc., New York, sets out the conventional method in which some seven time consuming essential steps are enumerate-d, some of which are entirely dependent upon the accuracy with which the individual recesses for the hinge butts are measured, marked and chiseled out, with no certainty that the final results will be uniformly accurate.

Insofar as the forming of the lock opening 34 and latch opening 30 are concerned, either may be formed before the other.

The door clamps 118, 119, and the cutters or drills that form the latch opening 30 and the lock opening 34 are fixed insofar as their movement longitudinally of the machine is concerned, and as the lock and latch are normally closer to the bottom of an installed door than to the top, the positioning of the ends of the door is made relative to the latch and lock openings.

When a door that is to be sw-ung in one direction is to be edged and the hinge recesses are to be formed, the jamb stop 127 and pawl 120 to position the door and hinge jamb are, for example, the nearest notch or recess in member as seen in FIG. 8, and may be seven inches from the end edge 124 whereas the shoulder 18 of the hinge jamb is closer to the jamb stop by the distance 6 (FIG. 18).

The next to the farthest notch 132 in this example will be eleven inches from the leading end of the door.

When the hinge jamb and door are to be prepared for swinging from the hinge jamb in a reverse direction to the above, the door 1, after edging, is moved to engage the door stop 245 (FIG. 4a) which is at the end of the bar 59 opposite to the end of feed or receiving end, said stop being swung down from the inoperative position shown in full line in FIG. 4a: to the dotted line position to engage the leading end of the door. This stop 245 is seven inches from the farthest notch 132 from the receiving end of the machine, and when the leading end of the door is against stop 245 the second notch 132 from the receiving end of the machine is eleven inches from the trailing end of the door.

A jamb stop 246 corresponds in structure to the jamb stop 127 and is also carried by the bar 128 at the end of the latter opposite to said stop 127. The stop 246 will perform exactly the same function as stop 127 to position shoulder 18 relative to the leading edge of the door to provide for space 6 when the door is in the frame. Of course, the hinge jamb is reversed end for end to the position shown in FIG. 8 when the stop 246 is used.

. Intermediate notches 132 provide for proper forming of recesses intermediate the butt receiving recesses already described, as in the case of doors having a central hinge.

The door stop 245 is, of course, in a position so that the lock opening and latch opening to be form-ed in the door will be closer to the trailing end of the door than to the leading end by the desired amount. Hence, once the door is clamped, the routing of the hinge recesses and the forming of the lock and latch openings may be per formed without changing the position of the door.

Referring to the modified form of the invention, the bar 59 (FIGS. 1, 8) is seen at 59 in FIG. 21 but in this instance said bar carries a horizontally extending strip 250 that has rigidly secured thereto at one end a pair of upstanding lugs 251, and a similar pair 252 is at the opposite end, while a third pair 253 is at a point intermediate the two end pairs (FIG. 24).

.The width of these lugs, transversely of strip 250, is equal to the spacing between the hinge jamb 254 and the door 255 (FIG. 21). In fact they function as a positioning means to properly space the door and jamb during the cutting of the butt receiving recesses, and this is also the correct spacing for securing the hinges to the door and jamb.

Each lug has an adjustable stop 256 (FIG. 22) that is adjustable Ilongitudinally of the strip 250, and each stop is held in adjusted position by nuts 257 respectively positioned at opposite sides of each lug.

The distance between and the relative positions of the stop members on each pair of lugs with respect to the door and jamb are critical.

j The strip 250 may carry a pin 258 at one end that is rigid therewith and that is adapted to fit in a hole in the horizontal upper leg of bar 59, thus removahly holding the bar against longitudinal movement (FIGS. 22, 24). A second opening may be formed in bar 59 at 259 (FIG. 24).

i For purpose of description, the pawl. 120 of FIGS. 1 and 8 is shown at 120 in FIG. 24 being at the left end of strip 250, as seen in the latter figure, while the stop 245 of FIGS. 1 and 4a is indicated at the right hand end of FIG. 24. y In the modified form of the invention these stops andthe jamb stops 127 (FIG. 8) and 246 (FIG. 4a) are unchanged and function exactly as already described. The jamb 254 indicated in FIG. 21 is for an outside door, which is the only difference between it and the jamb 7.

, The adjacent ends of the pair of stops 256 on each pair of lugs 251-253 are spaced apart a distance equal to the lengthof each of the hinge butts. These adjacent ends may be termed stop ends, or effective ends, since the opposite end of each stop performs no function.

The stop .256 on the lug 251 that is at the left end of strip 250 is the one nearest the door stop 120 and the distance between the stop or effective end of said step is preferably seven inches from the left hand end of door 14, as indicated in FIG. 24, or exactly the same distance as the left hand recess 132 in bar 125 of FIG.

18 8 is spaced from the trailing end of door 1, the bar 125, being. no longer used in the modified form of FIGS. 2'1-24.

The distance between the stop end of the stop mem-1 her 256 that is at the right hand end of strip (FIG. 24) is eleven inches from the leading end of the door 1 whenthe latter is against stop 120.

Referring now to FIG. 21 the router 262 is slidably mounted on the forward end of an arm 263 that extends rearwardly to a bar 264 that may generally be compared to bar 128 in FIG. 13. However, bar 264 is rotatably supported at its opposite ends in bearings 265 that are nigid on the frame of the machine. A pair of radially outwardly projecting ribs 266 integral with bar 264 extend longitudinally of the latter and rollers 267 carried by arm 263 roll on said ribs, thus supporting arm 263 for movement longitudinally of bar 264.

The arm 263 projects forwardly from bar 264,'and at each end of the bar are counterweights 268 that, in'

turn, are adjustablealong arms 269 that project rearwardly from and that are rigid with bar 264. These counterweight-s are to balance the .weight of the router and may be adjusted to automatically elevate the router when the latter is not in use.

In the present form of the invention, the jamb 254 is yieldably held against the lugs 252 by a plurality of expansion springs 270 each of which reacts between a stop 272 that is rigid with a horizontal plate 278 that, in turn, is rigid with the frame of the machine. Only one of these springs is shown in FIG. 21, and one or more cor responding springs are carriedon plate 273 at points spaced along the jamb.

-By the above structurethe jamb 273 is yieldably held during routing thereof for the hinge butts, and is held in the proper position relative to the door 255.

As already stated, the router 262 is movable on arm 263 longitudinally of the latter. Arm 263 is formed with a central slot 274 extending longitudinally thereof. The base plate 275 of the router extends across the upper side of said arm 263 and has extension 276 thereon projecting oppositely outwardly from the opposite side thereof at right angles to the length of arm 263. These extension-s 276 have downwardly directed runners 277 at their ends that function in the same manner as the runners 148 of FIG. 13, to ride on the door and jamb during the routing operation to control the depth of the recess. The router bit'27'8 (FIG. 22) willobviously cut into the jamb 254 to the depth it projects below the lower ends of runners 277. j

A tubular sleeve 281' is centrally secured to base plate 275 by a nut 279, and the bit shaft 280 extends through. said sleeve. A guide 282 rigid on said sleeve, is positioned within slot 274 in arm 263 and which guide has straight sides at opposite sides of-the slot to prevent ro-j tation of the'router while permitting it to move longi-. tudinally of arm 26%.

\ Rigidly secured on arm 263 is a depending plate 283. (FIGS. 22, 23) that is adapted to extend downwardly, into the space between the door and the jamb to a level below the stops 256 so as to engage said stops upon move: mentof the router and arm 26*3 longitudinally of the. dgor and jamb. i

Below the arm 263 is a plate 284 that is rotatable on the lower end of sleeve 281 and this plate carries a depending pin 285 that is adapted to perform the same function as the pin 158 of FIGS. 15, 16. A spring 286 connects between one of the runners or depth gauges 277 and plate 284, or if desired with pin 285 to yieldably hold the pin on a line that extends centrally through the drill bit, and that is at a right angle to arm 263 or parallel with the door and jamb to be routed out.

The plate 284 is cut out at one side to provide circumferentially facing shoulders 287 that are adapted to engage a rigid pin 288depending from the base plate 275, said pin being equally spaced between said shoulders when the router is inoperative, as seen in FIG. 23.

In operation, assuming the door and jamb are in the same position as indicated in FIG. 17 with respect to the door and jamb stops 15, -17 at the left hand end of the machine, and which stops are designated 120 and 127 in FIG. 8, the router 262 is swung down so that the depending member 283 is between the gauge screws 256 on cars 251. The router is grasped by handle 289 and may then be moved toward the jamb to rout out the recess for the hinge butt. The pin 285 will engage the jamb to rotate plate 284 until one shoulder 287 engages pin 288, which limits the width of the recess being routed out. The runners 277 will, .of course, ride on the jamb to control the depth of the recess, and the length of the recess will be determined by the spacing between the stops 256 on upstanding lugs 251. The jamb will be yieldably held or clamped against the ears 251-253 during the routing out of the recess.

The door edge is then routed out in the same manner, and the recesses in the door edge and the jamb will snugly receive the hinge butt.

The operator may then (in a two-hinged door) elevate the router by swinging it upwardly about the axis of bar 264, and move it to the right hand end of the machine where it will be swung down so that the member 283 is between the stops 286 carried by lugs 252, and the routing operation on the jarnb and door is completed.

In the case of a three-hinged door, the same operation is repeated by moving the router to position the control member 283 between stops 286 on lugs 253.

The router may then be released to swing to elevated position, and the hinges are quickly positioned and screwed to the jamb and door, after which the door and jamb may be quickly released and removed from the machine.

In the event the door being hung is one that is to be swung in a direction opposite to that of the door above described, it is merely necessary to move the strip 250 to the right and to reposition pin 258 in the opening at 259 (FIG. 24). By positioning the door against the end stop 245 land the jamb against the adjacent end stop 246, the butt receiving recesses formed by the router, as above described will be located correctly for the oppositely swinging door and hinge, with the right hand recess seven inches from the end of the door and the left hand recess eleven inches.

By the modified structure a roller mounted router is provided, and which router is counterbalanced so as to preclude accidental operation, while still maintaining ease of operation. Also the jamb is held against accidental movement during the routing operation, and the bar 125 of FIGS. 5, 8 is eliminated as a stop for the jamb and as a gauge member. Inasmuch as the critical edge of the jamb is the edge that faces the door, the use of the springs 270 and the spacing lugs 251-253 precludes any error due to any possible variations in the width of the jamb as well as insuring against accidental movement of the jamb during routing of the latter. The routing, of course, in the modified arrangement, occurs between the points where the lugs 251-253 of each pair thereof engages the jamb.

While we have shown a particular form of embodiment of our invention, we are aware that many minor changes therein will readily suggest themselves to others skilled in the art without departing from the spirit and scope of our invention.

We claim:

1. The method of prehanging a door on the hinge-jamb of a door frame that includes the steps of:

(a) supporting the door to be hung on edge in a horizontally extending position with the butt-facing surface of its hinge-edge facing upwardly;

(b) stationarily supporting the hinge-jamb having a butt-facing surface and to which hinge jamb said door is to be hung in a horizontally extending position offset longitudinally of said door and parallel with said hinge-edge and with its butt-facing surface facing upwardly at substantially the same level as said butt-facing surface of said hinge-edge on said door and offset laterally of said door a distance substantially equal to the normal spacing between said butt-facing surfaces when connected by the butts of door hinges when the said butts are coplanar;

(c) moving said door longitudinally thereof to a position alongside said jarnb and at the same time bevelling the longitudinally extending edge of said door that is opposite to said hinge edge according to the direction in which said door is to swing after being hung;

(d) then holding said door and said jamb stationary with their butt-facing upper surfaces coplanar and spaced apart a distance equal to the distance between the jamb and door after the door is hung and when the hinge butts are coplanar;

(e) then routing out recesses in said butt-facing upper surfaces for the hinge butts while said door and jamb are so held stationary relative to each other and finally, and while still holding said door and jamb stationary;

(f) securing said hinge butts in said recesses.

2. Apparatus for forming butt receiving recesses on one longitudinally extending edge of an elongated rectangular door and in the hinge-jamb from which said door is to be hung and for forming the latch and lock openings in said door along the opposite longitudinally extending edge of said door, comprising:

(a) a horizontally elongated stationary rigid frame one end thereof being a receiving end and the opposite end thereof being a discharge end;

(b) a door support on said frame extending longitudinally thereof for receiving and for supporting said door vertically disposed, but horizontally extending with said one edge facing upwardly, for horizontal movement of said door longitudinally thereof in one direction from said receiving end to said discharge end;

(c) door moving means on said frame adjacent to said receiving end for moving said door in said one direction;

(d) cutting means on said frame adjacent to said receiving end engageable with said opposite edge of said door for bevelling said opposite edge to the desired angle relative to the position of the hinges that are to hingedly connect said door with said hingejarnb, during movement of said door in said one direction and past said cutting means to a location on said door support for connecting a hinge-jamb thereto;

(e) a hinge-jamb support on said frame adapted to support said hinge-jamb thereon in a position parallel with and horizontally alongside said one edge of said door and spaced from the latter, when said door is in said location, a distance equal to the spacing bebetween said hinge-jamb and said door when said *hinge-jamb and said door are connected by butt hinges with the upper surface of said hinge-jamb that is adjacent to said door being horizontal and coplanar with the upper surface of said one edge whereby such butt-hinges may be directly secured to said hinge-jamb and door without moving the hingejamb and door relative to each other after the recesses for the butts of said hinges are formed;

(f) a router having a depending router bit and a carriage on said frame carrying said router as a unit, therewith for generally vertical movement from an elevated position in which said bit is spaced above said hinge-jamb and door to a lowered routing position in which said bit is adapted to rout out said upper surfaces of said door and hinge jamb to a depth substantially equal to the thickness of the butts 3,263,723 21 22 i of butt-hinges for connecting said door and hingesaid discharge end of the latter for movement toward jamb, and vice versa; and away from each other and from said door when (g) carriage supporting means on. said frame supportthe latter is positioned by said stop means for releasing said carriage for said generally vertical movement ably clamping said door therebetween to hold said of the latter and for reciprocable movement of said door rigid during the forming of said lock opening; carriage longitudinally of said door and jamb at all (q) said latch opening forming means including a vertimes; tically disposed power driven drill supported on said (h) said carriage and router including router supportframe for reciprocable vertical movement into and ing means supporting said router thereon for transout of the lower edge of said door when the latter verse movement of the latter transversely relative to is positioned by said stop means; the length of said frame when said butt is in rout- (r) separate means respectively connected with said ing position relative to said door and said hinge jamb; lock opening forming means and with said latch (i) means on said carriage for limiting the said transopening forming means for actuating them for said verse movement of router when in said routing posihorizontal and said vertical movement thereof. tion to distances in said door and hinge-jamb equal 5. Apparatus as defined in claim 4: to the widths of the butts of the butt hinges that are (s) said lock opening forming means and said latch to connect said door and hinge jamb; opening forming means including electric motors (j) control means on said frame at points spaced apart in an electrical circuit respectively movable horilongitudinally of the latter distances equal to the zontally and vertically with said drills and connected spacing of said butt hinges longitudinally of said with the latter for rotating the latter; door and jamb and means on said carriage in co- (t) switches in said electrical circuit and switch actuatoperative relation to said control means for limiting ing means for automatically closing said circuit to the movement of said router longitudinally of said each motor upon movement thereof and the drill conframe at each of said spaced points to a distance nected therewith toward said door for forming a said equal to the length of each of the butts of said butt lock opening and the latch opening in the latter and hinges when said router is in routing position; for automatically opening said circuit upon move- (k) stop means on said frame for positioning said door ment of each motor and the drill connected therewith and said hinge jamb longitudinally of said frame so away from said door. that said control means on said frame will be at p0si- 6. Apparatus as defined in claim 5: tions relative to said door and hinge jamb for rout- (u) separate manually actuatable means respectively ing out butt-receiving recesses in said upper surfaces connected with said lock opening forming means, of said door and hinge jamb at the correct points said latch opening forming means and said clamps along Said (1001 and Saidjflmb; for actuating said lock opening forming means and Separate latch and lock Opening means 011 Said said latch opening forming means for movement frame adjacent to the discharge end of the latter and t rd d away from said door and for actuating in positions relative to said stop means for drilling said clamps for movement into and out of door latch and 'lock openings in said door along said opclamping l tion, Posite longitudinally extending g of Said door, 7, Apparatus for preparing an elongated door, one Said p means being adapted to Position Said (1001 longitudinally extending edge of which has a butt-facing relative to said latch and lock forming means for the 4 urface for one b tt f b tt-hi es, nd an elongated formation of the latch and lock openings in said door hinge-jamb having a butt-facing surface extending lon i in the Correct predetermined relation to the recesses tudinally thereof for the other butt of said butt-hinges fOImed y Said Tolltel bit at the Same m Said P for hanging said door from said hinge-jamb, and which means positions said door for the formation of said hinge-jamb has a head-edge at one end for securement butt receiving recesses the latter; 4 of the head of a frame for said door thereagainst, said (m) holding means on said frame for releasably holdapparatus comprising;

ing said hinge-jamb and said door rigid and station- (a) rigid, Stationary frame;

ary relative to each other when said door is in said (b) door and hinge jamb Supports on Said frame for liocatbnion S.ald Floor support and.sald i q i supporting said jamb and said door alongside and Is on sand bulge-Jami) support during sald dnnmg parallel with each other in a horizontally extending of sald latch and llock openings by Sald latch and hinge-connectable position with said butt-facing surilock openmg formmg means faces on said jamb and door facing upwardly;

3. A aratus as defined in claim 2: (H) ga for removably securing said control means (c) a cutter for cutting butt receivmg recesses 1n sald butt-facing surfaces when said door and said jamb on said frame in two positions thereof relative to said frame longitudinally of the latter; are on said supports in said hinge-connectable position;

(0) said stop means being in two pairs thereof respec- (d) a carriage means movably supported on said frame tively adjacent to the receiving end of said frame and said discharge end for positioning said door and said supporting said cutter for movement as a unit therehinge-jamb in one of two positions according to the with longitudinally and transversely of said butt-facposition of aid o tr l me n whereby id butting surfaces and to a uniform predetermmed disreceiving recesses may be correctly positioned relatance into said jamb and door from said surfaces tive to the ends of said door and said hinge-jamb acwhen said jamb and door are supported in said cording to the direction in which the door is to swing hinge-connectable position for forming recesses for when it is connected with said hinge-jamb. the butts of said butt-hinges, and means supportlng 4. Apparatus as defined in claim 2: said carriage means for said movement;

(11) said lock opening forming means including a hori- (6) Control means respectively on said frame and on zontally disposed power driven drill supported on said said carriage means for positioning and for retaining frame for reciprocable movement transversely of the said cutter at the correct positions along said door length of said frame through a door when the latter and jamb for forming the butt-receiving recesses 1n is positioned by said stop means; said butt-facing surfaces on said door and jamb and (0) means for so supporting said power driven drill; for limiting the movement of said cutter longitu- (p) said holding means including a pair of opposed dinally and transversely of said door and jamb to disclamping plates supported on said frame adjacent to tances respectively equal to the length and width of 23 each butt-hinge at each of said last mentioned positions;

(f) door-moving means on said frame for moving said door longitudinally thereof to said hingeconnectable position relative to said jamb;

(g) spacing means on said frame adapted to extend between and to space said door from said hinge-jam-b when they are in said hinge-oonnectable position relative to each other;

(h) jamb-engaging means carried by said frame adapted to engage said jamb and to hold said jamb against said spacing means;

(i) door engaging means on said frame for releasably holding said door stationary substantially against said spacing means;

(j) said jamb-engagin-g means being yieldable for yieldably holding said jamb against said spacing means; (k) cutter means on said frame for bevelling the lower longitudinally extending edge of said door during movement of said door by said door engaging means to said hinge-connectable position;

(1) rigid :guide means adapted to engage said butt-facing surface on said door during movement of said door to said last mentioned position and References Cited by the Examiner UNITED STATES PATENTS 1,016,341 2/1912 Lowden 14427 2,427,081 9/1947 Zern 144-27 2,605,790 8/1952 Schwarzer 144-27 2,656,862 10/1953 Gellert et a1. 14493 2,801,655 8/1957 Zern 144-27 FOREIGN PATENTS 865,640 4/1961 Great Britain.

HAROLD D. WHITEHEAD, Primary Examiner.

25 WILLIAM W. DYER, JR., Examiner. 

1. THE METHOD OF PREHANGING A DOOR ON THE HINGE-JAMB OF A DOOR FRAME THAT INCLUDES THE STEPS OF: (A) SUPPORTING THE DOOR TO BE HUNG ON EDGE IN A HORIZONTALLY EXTENDING POSITION WITH THE BUTT-FACING SURFACE OF ITS HINGE-EDGE FACING UPWARDLY; (B) STATIONARILY SUPPORTING THE HINGE-JAMB HAVING A BUTT-FACING SURFACE AND TO WHICH HINGE JAMB SAID DOOR IS TO BE HUNG IN A HORIZONTALLY EXTENDING POSITION OFFSET LONGITUDINALLY OF SAID DOOR AND PARALLEL WITH SAID HINGE-EDGE AND WITH ITS BUTT-FACING SURFACE FACING UPWARDLY AT SUBSTANTIALLY THE SAME LEVEL AS SAID BUTT-FACING SURFACE OF SAID HINGE-EDGE ON SAID DOOR AND OFFSET LATERALLY OF SAID DOOR A DISTANCE SUBSTANTIALLY EQUAL TO THE NORMAL SPACING BETWEEN SAID BUTT-FACING SURFACES WHEN CONNECTED BY THE BUTTS OF DOOR HINGES WHEN THE SAID BUTTS ARE COPLANAR; (C) MOVING SAID DOOR LONGITUDINALLY THEREOF TO A POSITION ALONGSIDE SAID JAMB AND AT THE SAME TIME BEVELLING THE LONGITUDINALLY EXTENDING EDGE OF SAID DOOR THAT IS OPPOSITE TO SAID HINGE EDGE ACCORDING TO THE DIRECTION IN WHICH SAID DOOR IS TO SWING AFTER BEING HUNG; (D) THEN HOLDING SAID DOOR AND SAID JAMB STATIONARY WITH THEIR BUTT-FACING UPPER SURFACES COPLANAR AND SPACED APART A DISTANCE EQUAL TO THE DISTANCE BETWEEN THE JAMB AND DOOR AFTER THE DOOR IS HUNG AND WHEN THE HINGE BUTTS ARE COPLANAR; (E) THEN ROUTING OUT RECESSES IN SAID BUTT-FACING UPPER SURFACES FOR THE HINGE BUTTS WHILE SAID DOOR AND JAMB ARE SO HELD STATIONARY RELATIVE TO EACH OTHER AND FINALLY, AND WHILE STILL HOLDING SAID DOOR AND JAMB STATIONARY; (F) SECURING SAID HINGE BUTTS IN SAID RECESSES. 